EP1443627B1 - Generator mit Luftdeflektor - Google Patents

Generator mit Luftdeflektor Download PDF

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Publication number
EP1443627B1
EP1443627B1 EP04075119A EP04075119A EP1443627B1 EP 1443627 B1 EP1443627 B1 EP 1443627B1 EP 04075119 A EP04075119 A EP 04075119A EP 04075119 A EP04075119 A EP 04075119A EP 1443627 B1 EP1443627 B1 EP 1443627B1
Authority
EP
European Patent Office
Prior art keywords
pole
pole member
deflector
disc
generator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP04075119A
Other languages
English (en)
French (fr)
Other versions
EP1443627A2 (de
EP1443627A3 (de
Inventor
Duane Joseph Buening
Michael L. Hull
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Publication of EP1443627A2 publication Critical patent/EP1443627A2/de
Publication of EP1443627A3 publication Critical patent/EP1443627A3/de
Application granted granted Critical
Publication of EP1443627B1 publication Critical patent/EP1443627B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/24—Rotor cores with salient poles ; Variable reluctance rotors
    • H02K1/243—Rotor cores with salient poles ; Variable reluctance rotors of the claw-pole type

Definitions

  • the present invention relates to an improved generator. More specifically, the present invention provides an improved generator having an improved rotor assembly including an air deflector.
  • alternators include a stationary part, the stator, and a rotating part, the rotor.
  • the stator may include stationary coils or slotted pins or members that surround a rotor. As the rotor is turned by the car engine, the alternating magnetic field created by the rotor is intercepted by the stationary coils, pins or members, and current flows through the stator first in one direction, then in the other, resulting in alternating current. As the rotor is turned, air flow within the assembly will produce noise in the audible range that will emanate from the alternator assembly.
  • the rotor includes an electromagnet that is magnetized by current from the battery.
  • the electromagnet may include slip rings, rotor windings, and north and south pole members surrounding the rotor windings. Current from the battery flows through the slip rings to the rotor windings. North and south pole members have pole claws shaped like interlocking teeth surrounding the rotor windings. The north and south pole members create an alternating magnetic field as the rotor turns.
  • a housing surrounds the rotor and stator assembly.
  • the stator is fixed relative to the housing and the rotor shaft is rotatably mounted relative to the housing. Because the battery and electrical components in the car work on direct current (DC), the AC output of the alternator must be converted to DC. This is done with rectifiers which pass current in one direction only. Because, the components within the alternator produce heat and because the alternator operates under high under hood temperatures, a fan is included in the alternator assembly.
  • the fan may be placed inside or outside of the housing to increase airflow between the rotor and stator and to increase airflow through openings in the housing.
  • the fan blades may face inward toward the central portion of the alternator or outward away from the central portion of the alternator. Rotation of the fan increases airflow within the alternator and helps to reduce heat.
  • U.S. Patent 4,617,485 assigned to Nippondenso Co., Ltd., describes one attempt to reduce windage noise produced as a result of airflow interference between the rotor and the stator utilizing spacers centrally mounted between adjacent pole core claws.
  • the spacers are comprised of either discrete wedges mounted with an interference fit or are integrally formed into a ring. As described, the spacers are mounted centrally between opposing pole core claws. It appears that the spacers of this invention must be mounted relative to the claws either individually as separate wedges or as a ring. It appears that the direct fit between the spacers and claws will vary with manufacturing tolerances and temperature.
  • US 5 329 199 and US 6 369 486 disclose further examples of known generator constructions.
  • US 5 329 199 discloses a generator according to the preamble of claim 1.
  • the inventors of the present invention have recognized a need for an improved method of reducing noise emanating from the generator. Unlike known methods, Applicants have invented a deflector that does not require separate installation of individual wedges or a free floating ring. Further, the fit of the present invention will be more independent from temperature variations. The present invention also directs airflow in a manner different from known methods. Additional advantages of the present invention are described and will become apparent with reference to the drawings and specification provided herein.
  • An exemplary embodiment of the present invention includes a rotor and a deflector for use in an improved generator.
  • the rotor includes a rotor shaft extending in an axial direction and defining an axis of rotation, a first pole member mounted on a first end of the shaft and having a first set of teeth, and a second pole member mounted on a second end of the shaft and having a second set of teeth.
  • the first and second pole members are opposing one another and comprise north and south pole members.
  • the first set of pole claws and second set of pole claws are intermeshed and spaced apart from one another.
  • the deflector is supported about either of the first end or second end of the shaft and corresponds to the adjacent pole member mounted on the same end of the shaft.
  • the deflector is adapted to rotate with the corresponding pole member and includes a plurality of non-magnetic axial extensions having a base portion extending between adjacent pole claws of the corresponding member and terminating proximal an intermeshed pole claw of the opposing pole member.
  • the axial extensions provide a more uniform circumference creating more desirable airflow as the rotor rotates about its axis. The resulting airflow results in less noise as less air impinges against a surrounding stator.
  • the deflector axial extensions may further include a first side extension and a second side extension each further extending from the base portion and surrounding the intermeshed pole claw of the opposing pole member.
  • the deflector disc may further include at least one aperture for improving axial airflow within the pole members.
  • FIG 1 illustrates an exemplary generator 10 in which the improved rotor assembly of the present invention may be used.
  • the exemplary generator includes a stator assembly 15 surrounding a rotor assembly 20.
  • the rotor assembly 20 includes a shaft 21 supporting all rotating magnetic structures including conventional pole-members 16A and 16B, a rotor core 17 and a field coil 18 wound upon bobbin 12. Additionally, all other non-magnetic circuit rotating structures are carried, including air circulation fans 19 and 27 located at axially opposite sides of the pole-members, and a slip ring assembly 30 located at one extreme end of the shaft 21.
  • the fan 27 is formed from sheet metal stock and spot welded to the pole-member 16B while fan 19 is formed from an appropriate thermoplastic material and heat staked to tower extensions (not shown) from the field coil bobbin 12.
  • the shaft 21 is rotatably supported within a housing 26 by a pair of bearings 23 and 22.
  • Bearing 23 is located between the slip ring assembly 30 and the fan 19.
  • Coil leads 18A of field coil 18 are wrapped about respective posts 12A of bobbin 12 and pass through holes 13 in fan 19.
  • Slip ring assembly 30 is made of a pair of copper rings 31 each having a slip ring lead 32 joined such as by welding thereto. The copper rings and wires are molded into a thermoset material to complete the slip ring assembly 30.
  • slip ring assembly 30 is pressed onto the end of rotor shaft 21 and the slip ring leads 32 are routed into channels along the shaft 21 where they are joined, such as by twisting and welding, to the coil leads 18A of field coil 18 via a joint 24.
  • the joint 24 is then bent to the surface of the fan 19 and received in a pyramid shaped tab structure 25.
  • the joint 24 is then secured to fan 19 by ultrasonic welding of the plastic material of the tab 25.
  • Bearing 23 is assembled to pass over the slip ring assembly 30 to retain the lead wires 32 securely within the shaft channels.
  • the improved generator of the present invention includes an improved rotor assembly including the inventive air deflector described with respect to FIG. 3
  • FIG 2 provides an isometric view of an improved rotor assembly 210 for use in an improved generator.
  • the improved rotor assembly 210 includes a deflector 220 mounted on a rotor shaft 230 extending in an axial direction and defining an axis of rotation 240, a first pole member 250 mounted on a first end of the rotor shaft 230 and having a first set of pole claws 260, and a second pole member 270 mounted on a second end of the rotor shaft 230 and having a second set of pole claws 280.
  • the first pole member 250 and second pole member 270 are opposing one another and comprise north and south pole members.
  • the first set of pole claws 260 and second set of pole claws 280 are intermeshed and spaced apart from one another.
  • the deflector 220 may be supported about either of the first end or second end of the rotor shaft 230 and corresponds to the adjacent pole member mounted on the same end of the rotor shaft 230.
  • the deflector 220 of the present embodiment is mounted about the first end of the rotor shaft 230.
  • the deflector 220 is adapted to rotate with the corresponding pole member 250.
  • the deflector 220 includes a disc 340 suitable for mounting on a rotor shaft 230 and at least one axial extension 300 coupled to form a unitary component.
  • the disc 340 includes at least one disc aperture 390 for improving axial airflow through the generator.
  • the axial extensions 300 each have a base 310 extending between adjacent pole claws 260 of the corresponding member 250. A central portion 315 of the base 310 terminates proximal the end of an intermeshed pole claw 280 of an opposing pole member 270.
  • the axial extension 300 may further include a first side extension 320 and a second side extension 330 each further extending from the base 310 and surrounding the intermeshed pole claw 280 of the opposing pole member 270.
  • the deflector 220 provides a substantially uniform circumference creating more desirable airflow as the improved rotor assembly 210 rotates about its axis 240.
  • the deflector 220 increases axial rotor airflow and reduces noise sensitivity to stator winding patterns. The resulting airflow results in less noise as less air impinges against a surrounding stator.
  • the deflector 220 is mounted axially outward of the corresponding pole member and a fan 360 is mounted outward of the deflector 220 placing the deflector 220 between the corresponding pole member 250 and fan 360.
  • the fan blade 370 may be oriented adjacent a disc aperture 390.
  • a deflector 220 is shown mounted outward of a corresponding pole member 250, the deflector 220 may be adapted to be mounted axially inward of the corresponding pole member 250, placing the corresponding pole member 250 between the deflector 220 and the fan 360.
  • a fan 360 having a fan blade 370 extending in the outward direction is provided, the fan blade 370 may instead extend in the inward direction.
  • At least one inboard fan blade 370 may extend inward and at least one outboard fan blade 370 may extend outward of the disc 340.
  • the fan 360 of the present example may take the place of fan 27 of the exemplary generator of FIG 1 .
  • the fan 360 and deflector 220 may be formed from a variety of materials including without limitation metal or plastic material and coupled to form a unitary component. According to one example, the fan 360 and the deflector 220 may be formed from a single mold.
  • the generator may further include an opposing deflector 380 supported about the opposite end of the rotor shaft 230 adjacent the opposing pole member 270 providing an improved rotor including deflector 220 and opposing deflector 380 as embodied and described with respect to FIG 4 .
  • FIG 3 provides a partial view of an embodiment of a deflector 220 for use in an improved rotor assembly 210 according to the present invention.
  • the deflector 220 of this embodiment includes a disc 340 suitable for mounting on a rotor shaft 230 and at least one axial extension 300 coupled to form a unitary component.
  • the disc 340 includes at least one disc aperture 390 for improving axial airflow through the generator.
  • the disc aperture 390 is additionally adapted to receive a fan blade 370 that extends through the disc aperture 390.
  • the axial extensions 300 each have a base 310 extending between adjacent pole claws 260 of the corresponding pole member 250, a central portion 315 of the base 310 terminates proximal the end of an opposing pole claw 280 of an opposing pole member 270.
  • the axial extension 300 may further include a first side extension 320 and a second side extension 330 extending from the base 310 on each side of the central portion 315.
  • the first side extension 320 and second side extension 330 are positioned between a pole claw 260 of the corresponding pole member 250.
  • the deflector 220 provides a substantially uniform circumference creating more desirable airflow as the improved rotor assembly 210 rotates about its axis 240. In addition, the deflector 220 increases axial rotor airflow and reduces noise sensitivity to stator winding patterns.
  • the fan 360 is suitable for positioning axially outward of the corresponding pole member 250 and the deflector 220 is mounted axially outward of the fan 360, placing the fan 360 between the corresponding pole member 250 and the deflector 220.
  • the fan 360 is adapted to be mounted axially outward of the deflector 220 with the blade 370 of the fan 360 extending axially inward through the disc aperture 390.
  • FIG 4 provides an isometric view of an example of a deflector 380 and corresponding pole member 270 for use in an improved rotor assembly 210.
  • the deflector 380 of this example includes a disc 340 suitable for mounting on a rotor shaft and at least one non-magnetic axial extension 300 extending from the disc 340 to form a single unit.
  • the deflector 380 of this embodiment further includes at least one disc blade 400 extending from the disc 340.
  • the deflector 380 may additionally include a disc aperture 390 such as disc aperture 390 shown with respect to FIG 2 to improve axial air flow through the generator.
  • the axial extensions 300 each have a base 310 extending between adjacent pole claws 280 of the corresponding member 270. A central portion 315 of the base 310 terminates proximal the end of an opposing pole claw of an opposing pole member 250.
  • the axial extension 300 may further include a first side extension 320 and a second side extension 330 extending from the base 310 on each side of the central portion 315.
  • the first side extension 320 and second side extension 330 are of suitable dimension to fit between a pole claw 280 of the corresponding pole member 270 and the opposing pole claws 260 of the opposing pole member 250.
  • the deflector 380 is mounted utilizing mounting holes 350.
  • a post extending from field coil bobbin 12 in FIG 1 extends through mounting holes 350 and is welded to the deflector 380.
  • the deflector 380 provides a substantially uniform circumference creating more desirable airflow as the improved rotor assembly rotates about its axis.
  • the deflector 380 increases axial rotor airflow and reduces noise sensitivity to stator winding patterns. The resulting airflow results in less noise as less air impinges against a surrounding stator.
  • the disc 340 is mounted axially outward of the corresponding pole member 270 and the disc blades 400 extend axially outward from the disc 340.
  • a deflector 380 mounted outward of a corresponding pole member is shown, the deflector 380 may be adapted to be mounted axially inward of the corresponding pole member 270. Because the disc blades 400 are included on the disc 340 of the deflector 380, the deflector 380 of the present example can be substituted in place of fan 19 of the exemplary generator of FIG 1 .
  • the deflector 380 can be formed from a variety of materials including without limitation plastic or metal.
  • the disc blade 400 may instead extend axially inward from the disc 340. Additionally, according to one example, at least one inboard disc blade 400 may extend inward and at least one outboard disc blade 400 may extend outward of the disc 340.
  • the deflector may additionally include a cylindrical mounting extension 420 and a relief feature 410 for routing a lead wire within a channel formed by the relief feature 410.
  • the relief feature intersects the mounting extension 420 to create a passage 430 for the lead wire.
  • the relief feature 410 is enlarged to accommodate a coiled lead wire.
  • An exemplary relief feature 410 is shown with respect to FIG 4 .
  • FIG 5 provides a rear inside view of FIG 4 showing the inside of the pole member 270 and the deflector 380 positioned behind the pole member 270, outboard of the pole member 270.
  • the axial extensions 300 each have a base 310 extending between adjacent pole claws 280 of the corresponding member 270, a central portion 315 of the base 310 is sized to terminate proximal the end of an opposing pole claw of an opposing pole member.
  • the axial extension 300 may further include a first side extension 320 and a second side extension 330 extending from the base 310 on each side of the central portion 315.
  • the first side extension 320 and second side extension 330 are of suitable dimension to fit between a pole claw 280 of the corresponding pole member 270 and the opposing pole claws 260 of opposing pole member 250.
  • the deflector 380 is mounted utilizing mounting holes 350.
  • a post extending from field coil bobbin 12 in FIG 1 extends through mounting holes 350 and is coupled to the deflector 380.
  • the deflector 380 is formed of a thermoplastic material and is ultrasonically welded to the post.
  • the deflector 380 of this example provides a substantially uniform circumference creating more desirable airflow as the improved rotor assembly rotates about its axis.
  • the deflector 380 increases axial rotor airflow and reduces noise sensitivity to stator winding patterns. The resulting airflow results in less noise as less air impinges against a surrounding stator.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Motor Or Generator Cooling System (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Claims (7)

  1. Generator, umfassend:
    eine Läuferwelle (230), die in Axialrichtung verläuft und eine Drehachse (240) definiert, und ein erstes Polelement (250) und ein zweites Polelement (270), die jeweils an der Läuferwelle (230) montiert sind und einander entgegengesetzt sind, wobei das erste Polelement (250) einen ersten Satz Polklauen (260) hat und das zweite Polelement (270) einen zweiten Satz Polklauen (280) hat, wobei der erste Satz Polklauen (260) und der zweite Satz Polklauen (280) axial einwärts verlaufen und ineinandergreifend und voneinander beabstandet sind,
    einen Ablenker (220), der entweder dem ersten Polelement (250) oder dem zweiten Polelement (270) entspricht, wobei der Ablenker (220) Folgendes aufweist:
    eine Scheibe (340), die neben dem entsprechenden Polelement um die Läuferwelle (230) gelagert ist und zum Drehen mit dem entsprechenden Polelement ausgeführt ist, und
    mehrere nichtmagnetische axiale Fortsätze (300), die sich von der Scheibe (340) erstrecken, wobei die nichtmagnetischen axialen Fortsätze eine Basis (310), die zwischen benachbarten Polklauen des entsprechenden Polelements verläuft, und einen zentralen Teil (315) aufweisen, der neben einer eingreifenden Polklaue des entgegengesetzten Polelements endet,
    dadurch gekennzeichnet, dass die Scheibe (340) ferner mehrere Scheibenöffnungen (390) aufweist, wobei der Generator ferner einen Lüfter (360) mit sich durch die Scheibenöffnungen (390) der Scheibe (340) erstreckenden Lüfterflügeln (370) aufweist.
  2. Generator nach Anspruch 1 mit einem entgegengesetzten Ablenker (380), der dem ersten Polelement (250) bzw. dem zweiten Polelement (270) entspricht, wobei der entgegengesetzte Ablenker (380) Folgendes aufweist:
    eine Scheibe (340), die neben dem entsprechenden Polelement um die Läuferwelle (230) gelagert ist und zum Drehen mit dem entsprechenden Polelement ausgeführt ist, und
    mehrere nichtmagnetische axiale Fortsätze (300), die sich von der Scheibe (340) erstrecken, wobei die nichtmagnetischen axialen Fortsätze eine Basis (310), die zwischen benachbarten Polklauen des entsprechenden Polelements verläuft, und einen zentralen Teil (315) aufweisen, der neben einer eingreifenden Polklaue des entgegengesetzten Polelements endet.
  3. Generator nach Anspruch 1, wobei wenigstens einer der mehreren nichtmagnetischen axialen Fortsätze (300) einen ersten Seitenfortsatz (320) und einen zweiten Seitenfortsatz (330) hat, die sich weiter von der Basis (310) erstrecken und jede Seite der eingreifenden Polklaue des entgegengesetzten Polelements umgeben.
  4. Generator nach Anspruch 1, bei dem der Ablenker (220) axial auswärts von dem entsprechenden Polelement auf der Läuferwelle (230) montiert ist.
  5. Generator nach Anspruch 1, bei dem der Ablenker (220) axial einwärts von dem entsprechenden Polelement auf der Läuferwelle (230) montiert ist.
  6. Generator nach Anspruch 1, bei dem die Scheibe (340) des Ablenkers (220) ferner ein Aussparungsmerkmal (410) und einen zylindrischen Befestigungsfortsatz (420) aufweist, die sich schneiden, um einen Anschlussdrahtdurchgang (430) zu bilden.
  7. Generator nach Anspruch 1, bei dem sich wenigstens ein innenliegender Lüfterflügel (370) axial einwärts von dem Scheiben-(340)-teil erstreckt und wenigstens ein außenliegender Lüfterflügel (370) sich axial auswärts von dem Scheiben-(340)-teil erstreckt.
EP04075119A 2003-01-29 2004-01-16 Generator mit Luftdeflektor Expired - Lifetime EP1443627B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US354635 2003-01-29
US10/354,635 US6781262B2 (en) 2003-01-29 2003-01-29 Generator and air deflector

Publications (3)

Publication Number Publication Date
EP1443627A2 EP1443627A2 (de) 2004-08-04
EP1443627A3 EP1443627A3 (de) 2005-11-30
EP1443627B1 true EP1443627B1 (de) 2009-03-25

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Application Number Title Priority Date Filing Date
EP04075119A Expired - Lifetime EP1443627B1 (de) 2003-01-29 2004-01-16 Generator mit Luftdeflektor

Country Status (3)

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US (1) US6781262B2 (de)
EP (1) EP1443627B1 (de)
DE (1) DE602004020134D1 (de)

Families Citing this family (10)

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FR2866993B1 (fr) * 2004-02-27 2006-04-28 Valeo Equip Electr Moteur Ensemble rotorique dont au moins un espace intergriffes est obture par le ventilateur
WO2006016394A1 (ja) * 2004-08-09 2006-02-16 Mitsubishi Denki Kabushiki Kaisha 回転電機
JP2007329989A (ja) * 2006-06-06 2007-12-20 Denso Corp 車両用交流発電機の回転子
JP4483845B2 (ja) * 2006-09-12 2010-06-16 株式会社デンソー 車両用交流発電機
US20080315730A1 (en) * 2007-06-25 2008-12-25 Waddell Simon L High speed generator rotor field coil lead retention system
FR2988236B1 (fr) * 2012-03-16 2014-03-28 Valeo Equip Electr Moteur Ensemble de flasques de rotor de machine electrique tournante comportant des orifices asymetriques favorisant un flux d'air axial a l'interieur du rotor et rotor de machine electrique tournante associe
FR2988238B1 (fr) * 2012-03-16 2016-06-24 Valeo Equip Electr Moteur Ensemble de flasques de rotor de machine electrique tournante comportant des pales axiales de ventilation favorisant un flux d'air axial a l'interieur du rotor et rotor de machine electrique associe
GB2525143B (en) * 2014-01-06 2020-06-24 Spinetic Energy Ltd A generator
JP6030686B2 (ja) * 2015-03-26 2016-11-24 本田技研工業株式会社 エンジン駆動発電機
JP5985691B1 (ja) * 2015-03-26 2016-09-06 本田技研工業株式会社 エンジン駆動発電機

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JPS6048365U (ja) * 1983-09-05 1985-04-05 三菱電機株式会社 回転電機の回転子
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JPS62189928A (ja) * 1986-02-12 1987-08-19 Mitsubishi Electric Corp 誘導子形交流発電機の回転子
JP2926972B2 (ja) * 1990-11-08 1999-07-28 株式会社デンソー 交流発電機
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JP3435075B2 (ja) * 1998-09-07 2003-08-11 三菱電機株式会社 車両用交流発電機
FR2786624B1 (fr) * 1998-11-30 2001-02-16 Valeo Equip Electr Moteur Rotor d'alternateur de vehicule a aimants permanents intercalaires
US6580187B2 (en) 2000-01-14 2003-06-17 Delphi Technologies, Inc. Rectifier assembly for an air-cooled generator
US6563247B2 (en) 2001-05-18 2003-05-13 Delphi Technologies, Inc. AC generator having stator assembly with improved phase coil insertion order to reduce noise

Also Published As

Publication number Publication date
US6781262B2 (en) 2004-08-24
EP1443627A2 (de) 2004-08-04
US20040145255A1 (en) 2004-07-29
DE602004020134D1 (de) 2009-05-07
EP1443627A3 (de) 2005-11-30

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